Construction of the California Precast Concrete Pavement Demonstration Project - Concrete - Pavements - FHWA

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Construction of the California Precast Concrete Pavement Demonstration Project

July 2007
FHWA-IF-06-010

TABLE OF CONTENTS

LIST OF FIGURES

Figure 1. Illustration. Typical precast prestressed panel layout.
Figure 2. Illustration. Typical base panel.
Figure 3. Illustration. Typical joint panel.
Figure 4. Illustration. Typical central stressing panel.
Figure 5. Illustration. Coupler used to join post-tensioning strands together in the stressing pockets.
Figure 6. Illustration. Flowchart for the overall construction process.
Figure 7. Illustration. Location of the California precast pavement demonstration project.
Figure 8. Illustration. Cross section of the original (proposed) pavement structure for widening I‑10 (1 ft = 0.305 m).
Figure 9. Illustration. Cross section of the precast panels, incorporating the change in cross slope into the surface of the panel.
Figure 10. Photo. Precast panel at the fabrication plant after removal from the forms.
Figure 11. Illustration. Support structure for equivalent pavement design (subgrade, class 3 aggregate base, and lean concrete base), topped by either jointed concrete pavement or precast prestressed concrete pavement.
Figure 12. Equation. Fatigue life prediction based on number of 8.2-Mg (18 kip) ESALs experienced by the pavement.
Figure 13. Equation. Prediction of concrete temperature based on ambient temperature.
Figure 14. Equation. Equation for estimation of modulus of rupture from
compressive strength.
Figure 15. Illustration. Keyway dimensions for the precast panels.
Figure 16. Photo. Keyway of two assembled panels at the fabrication plant.
Figure 17. Photo. Typical central stressing panel at the fabrication plant prior to shipment.
Figure 18. Illustration. Expansion joint detail for the California pilot project.
Figure 19. Photo. Typical joint panel at the fabrication plant prior to shipment.
Figure 20. Photo. Placement of concrete for a base panel.
Figure 21. Photo. Screeding the surface of a joint panel.
Figure 22. Photo. Removal of a panel from the forms after curing.
Figure 23. Photo. Mid-panel hairline crack after curing.
Figure 24. Photo. Panels were shipped to the job site one per truck.
Figure 25. Photo. A precast panel is lifted off the truck and over the concrete barrier and set in place.
Figure 26. Photo. Workers detach the lifting lines from a precast panel. Note the
polyethylene sheeting, rolled out just prior to placement of each panel.
Figure 27. Photo. Lowering a panel into place.
Figure 28. Photo. Workers apply epoxy to the joint prior to assembling the panels.
Figure 29. Photo. Workers use temporary post-tensioning to pull the panels together as they are assembled.
Figure 30. Photo. Workers feed the post-tensioning strands into the ducts at the central stressing pockets and push them through the ducts to the anchors.
Figure 31. Photo. A “dogbone” coupler is used to splice the post-tensioning tendons together in the stressing pockets. The stressing ram tensions both tendons at the same time through the coupler.
Figure 32. Photo. A monostrand stressing ram is used to tension each of the post-tensioning tendons.
Figure 33. Illustration. Mid-slab anchor at the central stressing pockets.
Figure 34. Photo. Workers fill the post-tensioning pockets with a “pea gravel” concrete mixture after post-tensioning.
Figure 35. Photo. Corner break that occurred during panel installation—the only major distress encountered.
Figure 36. Photo. Grout is pumped into one end of the post-tensioning tendon at the stressing pocket until it flows out of the far end.
Figure 37. Illustration. Chain of three iButton® sensors for top, mid-depth, and bottom slab temperatures (1 mm = 0.039 in.).
Figure 38. Illustration. Typical layout for a set of iButtons ® with the twisted-pair wire from the sensors routed to a junction box at the end of the panel (edge of the pavement).
Figure 39. Graph. Temperature history for one set of temperature sensors during casting and storage at the precast plant.
Figure 40. Graph. Temperature history for two different mid-depth sensors prior to opening to traffic.
Figure 41. Photo. Dial calipers were used to measure expansion joint movement using Demec points on either side of the joint as gage points.
Figure 42. Graph. Relative total movement of three expansion joints with temperature at the north, middle, and south ends (measurements obtained August 26–27, 2004).
Figure 43. Illustration. Project Level condition survey after construction and location of temperature sensors.
Figure 44. Photo. Finished precast pavement just prior to opening to traffic.

LIST OF TABLES

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Updated: 04/07/2011

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Sam Tyson
Office of Asset Management, Pavement, and Construction
202-366-1326
E-mail Sam

United States Department of Transportation - Federal Highway Administration